E,F) scanning electron microscopy (SEM) images of finished Zr-BMG flow fieldFuel cell power sources can be an efficient technology for direct conversion of various forms of hydrocarbon fuels to electrical power, and in the case of hydrogen fuel, could provide one of the greenest energy sources available. Fuel cells have the potential to impact application areas including grid scale, automotive, and portable electronics, but the predicted impact has not yet been realized as the manufacturing, cost, and reliability of fuel cell components has not matured sufficiently to be competitive with other power sources. Fuel cell optimization challenges remain due to the need to create a hierarchical materials structure at the triple-phase boundary. This facilitates effective mass transport of reactants and byproducts with a materials region that incorporates catalyst, electrolyte, and conductor properties within a porous diffusion scaffold. Integrating these nanoscale features with microscale flow field channels requires multiple process steps and materials layers that are typical of fuel cell architectures.
